Galvorn wire is changing the game in high-performance applications, offering a revolutionary combination of strength, light weight, and conductivity, unlike any other material. As with other conductive materials, working with Galvorn requires precision.
Regardless of material, improper termination can degrade a conductor’s performance, leading to signal loss, high resistance, and mechanical failure. This blog—and the accompanying video—will walk you through the proper techniques for creating reliable, high-integrity connections on both uninsulated and insulated Galvorn wire.
What Exactly is Galvorn Wire?
Before we start stripping and crimping, it helps to understand what you're working with.
Galvorn is solid carbon that comes in the form of flexible, textile-like fibers (or flexible films). It is composed of densely packed, highly aligned carbon nanotubes (CNTs). Typically we braid or twist the fibers into yarns, aka carbon nanotube (CNT) wire. Galvorn film can be wrapped around conductive wire for EMI shielding that meets Mil specs, while offering 35-60% overall cable weight savings (as well as superior heat dissipation, cut-resistance, and flame resistance).
Galvorn’s superior flexibility, cut-resistance, and flame resistance (Galvorn does not melt!) require different approaches to termination than what you might be used to with metals. With proper termination you can avoid insufficient retaining force, damaged fibers, or inadequate electrical contact.
Tools and Materials Checklist
Preparation is key. Have all these items ready before you start:
| Item | Purpose | Key Requirement |
| Galvorn Wire | The star of the show! | Uninsulated or insulated samples. |
| Connectors/Terminals | The end point for your connection. | Use high-quality, precision terminals designed for mechanical splices or specialized crimping. We recommend gold-plated connectors. |
| Insulation Stripper | For removing the outer jacket. | Precision strippers are mandatory to avoid nicking the underlying wire. We use the Jonard Tools ST-500 Adjustable Precision Wire Stripper. |
| Crimping Tool | For mechanical termination. | Use a tool with adjustable or calibrated dies suitable for low-diameter, high-strength materials. Standard crimpers may deform the material and fail to grip or cut the insulation correctly. |
| Heat Shrink Tubing | For insulation and strain relief (insulated wire). | Appropriate diameter, shrink temperature, and material for the operating environment. |
| Safety Gear | Your protection. | Safety glasses. |
STEP-BY-STEP
Terminating Uninsulated Galvorn Wire
When working with uninsulated Galvorn, our primary goal is to ensure maximum mechanical grip and minimum electrical contact resistance.
- Prep the Terminal: Ensure the terminal barrel is clean and free of debris.
- Clean the Wire End: Ensure the wire is clean and free of debris. We recommend using gloves to avoid oils from handling getting on the wire, and/or alcohol to remove any oils that have already gotten on the wire.
- Insert the Wire: Carefully slide the uninsulated Galvorn wire into the terminal barrel. Make sure the wire is inserted fully, making contact with the stop inside the barrel. This is critical for ensuring the crimp engages the maximum surface area.
- The Precision Crimp:
- Insert the terminal and wire into the correct crimping die.
- CRITICAL: Apply the crimp force gradually and precisely. Use the crimping force specified by the manufacturer.
- Quality Check: Perform a gentle pull test. The connection must hold firmly without any slippage. You can also use a multimeter to ensure r continuity and check resistance.
STEP-BY-STEP
Terminating Insulated Galvorn Wire
The process for Galvorn insulated wire is similar, but includes a crucial insulation stripping step that requires extreme care.
The Critical Step: Insulation Stripping
You must remove the insulation without letting the tool catch, or cut, the individual smaller fibers (aka strands) that construct the Galvorn wire. Doing so avoids fraying and maintains the strength and conductivity of the Galvorn wire.
- Measure the Strip Length: Determine how much insulation needs to be removed based on the terminal size. Only strip the minimum length required.
- Use a Precision Tool: Using a mechanical stripper, select the die size that just engages the insulation and adjust the stop to prevent over-cutting.
- Carefully Remove Insulation: Pull the insulation straight off.
Connecting and Sealing
- Attach the Terminal: Follow the insertion and crimping steps exactly as detailed for uninsulated wire above.
- Strain Relief and Sealing: Slide a piece of appropriately sized heat shrink tubing over the connection. The tubing should cover the entire crimped area and extend significantly past the insulation line.
- Shrink the Tubing: Use a heat gun (not a lighter!) to evenly shrink the tubing, providing excellent environmental protection and, most importantly, strain relief. This protects the point where the insulation ends and the termination begins from exposure.
PRO-TIP
Why Standard Tools Don't Work
Many failures with advanced wires like Galvorn are due to using tools designed for soft copper.
- Copper Crimping Dies: Avoiding crimps designed for a wide range of wire sizes, as they are more prone to over or under crimp.
- Standard Wire Strippers: Wire strippers often rely on the stiffness of copper to support the insulation during the cut. Due to Galvorn's flexible nature, inadequate tools can lead to shallow or asymmetrical cuts, as well as tear or stretch insulation.
- Wire Strippers with Gripping Jaws: Wire strippers that have gripping jaws also have a tendency to nick and stretch the insulation rather than producing a clean cut.
The takeaway? Invest in high-quality, adjustable, or specialized tooling to protect the integrity of your Galvorn wire.
Watch the Full Process!
Seeing this process in action is the best way to master the technique. Watch the videos below for a step-by-step demonstration of stripping and terminating both types of Galvorn wire, ensuring you get a reliable, high-performance connection every time.
How to Terminate Galvorn Uninsulated Wire
How to Terminate Galvorn Insulated Wire
Note: At minute 1:15 in both videos we also show how to crimp Galvorn to a copper wire.Â
It is common to use specialized wire only where necessary. For instance, in a furnace where Galvorn’s environmental compatibility would be crucial, the material would likely be confined to the hot region. In such cases, a "pig tail," a short piece of copper wire, can be soldered to a PCB, while Galvorn is attached to the copper wire via crimping. Crimping to copper wire is also relevant for connecting to devices where the manufacturer has pre-attached wires. Devices such as thermocouples, which are often made of wire, would require a Galvorn-to-wire joint at some point.Â
As with all conductive materials, proper termination of Galvorn wire is essential for unlocking its full potential in high-performance applications. By following these techniques for both uninsulated and insulated Galvorn wire, and investing in the right tools, you can ensure robust, reliable, and high-integrity connections. We hope this guide helps you achieve optimal performance with this remarkable material. If you have additional questions not addressed here, please do not hesitate to contact us. We are here to support you!
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